Art of manufacturing artificial monoliths.



A. JEN SEN.

ART OF MANUFACTURING ARTIFICIAL MONOLITHS.

APPLICATION FILED 33.18, 1910.

1,050,946. Patented Jan. 21, 1913.

wzimssea I Emma miar flndrewjemezz the accompanyin ANDREW JENSEN, OF NA TICK, MASSACHUSETTS.

ART OF MANUFACTURING ARTIFICIAL MONOLITHS.

Specification of Letters Patent.

Patented Jan. 21,1913.

Application filed February 18, 1910. Serial No. 544;,688.

To all whom it may concern:

Be it known that I, ANDREW Jansen, a citizen of the United States, and a resldent of .Natick, in the county of Middlesex,

The character of the invention may be best understood by reference to the following description 'of anillustrat-ive method of manufacture when taken in connection with drawing wherein: Figure 1 is a si mold which may be'u'sed in the method embodying the invention; and Fig. 2 is a vertical section of a moldand plate which ma be used in the method. In the manufacture of monolithsas concrete blocks or other forms, it is very desir-able to produce a block or other form having a hard, dense surface layer or surface which will not crack; which will effectually resist the attacks of the weather and which will have a finished and attractive appearance. By the method which I will "now describe embodying my. invention alhlock or other form may be made having the above and other qualities.

In carrying out my method a thin layer of wetfiuxive wet concrete mixture is placed on aisurfacc of a form or pattern which may vary accordin to the nature of face it is desired to pr uce. If, for example, flat; smooth surfaces are desired the mixture is placed on a flat plate such as A which preferably should be of hard, nonporous material and should hold its shape without warping or distortion. A steel plate or galvanized iron plate is found to he very satisfactory but I prefer to use for this purpose a thin cement plate as is made by this method as more fully hereinafter described. When this thin cement plate is used for this urpose it may be reinforced withmetal lathing or expanded metal if desired. The plate or other surface used may be covered with -an insulation coating of representing like plate e elevation of vibrator and face, thereby bringing a layer pure cement to said surface. At the-same.

tallow, suet of-beef or other lubricant to fill any pores which might be present-in said surface and prevent the water or other ingredlents of the mixture from entering said pores and to provide a surface which will enable the removal of the layer from said plate to, be readily effected at the later stage in the process, as more fully hereinafter de-- scribed.

It is foundv infpractice that excellent results are obtained from a wetconcretemixture comprising one part .of cement to two parts of gravel or crushed stone of a size which may vary and may depend somewhat on the thickness of the layer to be used. It is not necessary to distribute the wet con:

crete mixture carefully and evenly on the but itwill sutfice to distribute smallmixture at random on the quantities of said been placed plate. The wet mixture having on the plate the latter is then vibrated causing the mixture to spread evenly over said plate with a substantially uniform thickness. It will be understood that the mixture preferably is not confined at the edges of the plate but is free todistribute itself on the latter and the thickness of the layer will" be determined somewhat by the consistency of the mixture and the time of vibration of the plate. Thevibration of the latter will cause the heavier particles in the mixture to tend to settle to the bottom of the layer and into close contact with. the surface of said plate and cause the finer particles towork;

their way through said heavier particles,

and the finest articles, being of cement, will come into intimate contact withsaid surtime the water-in the mixture will tend to rise u through the layer to the surface thereo The best concrete is obtained if there is suflicient water in this mixture so that when the plate is vibrated the water will rise to the surface clear and without carrying slimes or particles with'it. The settling of the particles into close contact with said plate and with each other will, of course, drive out air as well as water and prevent the inclusion in said layer of interstices or air pockets. As the layer is thin it is necessary to vibrate the plate only for a very short time in order to drive outthe air and water sufliciently, a vibration for about thirty seconds being usually sufiicient.

The plate may be vibrated by any suitable of practically v vertically by eccentrics 13 fast on said shafts and journaled in bearings 15 secured to the To rotate the.

lower horizontal joists 5. shafts 11 simultaneously, the lattersmay be provided with sprocket wheels 17 fast on 15 said shafts and connected by a suitablesprocket chain 19, one of said shafts being provided with a suitable driving pulley (not shown). It will be apparent that when said shafts 11- are rotated the posts 9 will 20 be vibrated vertically and transmit vibratory movements to the table 1. To lift the table from its seat on said vibratory posts 9, suitable lifting pins 21 may beset in vertical holes in the upper joists 5 and may he lifted into engagement with the table undercleats 7 by bell crank levers 23 fulcrumed on brackets 25 depending from one of said joists 5. The short arms of said bell cranks engage the lower ends of said pins. while their long arms are connected by a link 27 so that they may be simultaneously rocked to lift the table evenly as desired. To rock said bell cranks and hold the same in position, a handle 29 is secured to, or may beintegral with, one of said cranks and may be held in its positions of adjustment by a spring pressed dog 31 on said handle cooperating with a ratchet 33 secured to one of said joists 5. The plate or mold to be vibrated may be guided and held in place on the table by-suitableguide rollers 35 on studs 37 projecting upwardly from said table.

In practice the plate is preferablvpositioned on the vibrator (Fig. 1) and then the wet concrete mixture is placed on the H plate. After the plate has been sufficiently vibrated as described, it is removed from the vibrator and set aside or placed in a suitable rack, whereupon some of the water or moisture which has accumulated on the surface of said layer will goback ,into the mixture to crystallize the cement and some of the water will evaporate. As a result the layer stiifens somewhat. The vibration of the layer as described will drive out the air from between the layer and the plate to such an extent that the layer will lie in intimate contact with said plate, the atmospheric pressure on the surface of said layer contributing to its retention on said plate. In fact, the layer sticks so closely to said plate that said layer and plate may 'be roughly moved about without liability 85 of one separating from another. If it is de sired to use 'the la yer for slabs or tiles it is now. permitted to harden, but if it is desired to use the layer for a facing of a .,blo c k, wall .orot-her. form the layer is not mixture isfil'led into the mold on top of said 80 llayerato constitute the body of the block 1 and the table is again vibrated for a short period, a time of about sixty seconds being .crdinarily, .suflicient to settle. or :pack the particles of the body of .the block and effect 5 the. adhesion of the latter to. said layer or veneer.

In practice the mixture forming the body of the block or backing. for the layer may consist of one part cement, two parts sand and three parts crushed stone or gravel, although any good. concrete mixture mlght be used. The body mixture should be moist, but considerably drier and stifl'er than the mixture used in making the surface layer, said body. being sufficiently stiff if somewhat harder than ordinary, mortar. After the body and veneer have been vibrated together as described, the plate andflask may be slid or otherwise removed from the vibratory table and the flask may be removed at once from the block or other form which may then be placed aside to harden. The hardening may be accelerated if desired by steaming, as by placing-the block in a steaming room. The plate must remain on the block until the latter. has-hardened, The plate-may be then pulled off of said block leaving the plate. per'fectlyclean and without any portion of the fading of the block adhering thereto. The insulation coating previously referred to which v was spread on said plate and the hardness, and denseness of the facing layer contribute to this result The face of the block thusmade is extremely hard and dense throughout and presents a very finished and attractive appearance. The face ofthe block requires no further finishing but is complete and ready for use. It is found 'that this hard facing done not crack but maintains a smooth and continuous surface. Probably one of the reasons for this is the fact that in vibrating the wet layer on the plate the particles settle closely together and to the surface of said plate so that they have a strong adherence enabling them to effectually resist shrinkage and cracking. A veneer made by the process described is so hard, dense and smooth that as stated above other plate and vibrated as before. The

former plate with its layer adhering thereto is then set on edge in the flask with the plate against one side of the flask, and the mixture for the body of the block is filled in and vibrated and the flask removed thereby forming a block having two hard facings. Other hard faces may be made in a similar manner. When side facings are being made the layer shouldbe of a thinness suflicient to permit it to remainon the plate when the latter is set on edge in the mold. The adjoining sides of the veneers may be smoothed" or beveled off to form a clean mortised joint if desired. The hard surface may be given an ornate appearance simulating marble and graining or other color efiects byplacing splotches, lines or streaks of color on the surface of the plate. When the layer' of the wet mixture is vibrated into close adherence to said plate the colors may be spread or be diffused causing them to blend and present very pleasing ornamental effects. The suet, tallow or other insulation coating may be of a nature to affect the appearance of the .surface. when suet is used it is found that when the plate is removed the surface has a sort of sheen or polished appearance. It .will be understood that the hard layer of veneer maybe applied to various 'uses such as intcrior and exterior Walls, solid walls having a finished surfacing on their outer and inner sides, ceilings, floors, walks and tiles. Rough stone or other surfaces may be imitated with absolute accuracy) due to the close conformity of the layer toi the surface or pattern imitated, had by the settling of the particles thereto under the vibration of the layer, as described. A block ;or other form having a layer such as is made by the process described herein is more lastin durable and permanent than any other nown to me. 1

In making an entire wall in one mold a layer or layers of the wet mixture are vibrated and allowed to stand a short time as before and the plates are then placed in the mold.- The concrete mixture constituting the body of the wall is then filled in, but in this case the body of the wall would be tamped into close adherence with said layer. The plate or plates would remain on the wall until after the latter has hardened, the

- 1. An improvement in For example,

plate being removed when the mold f is rcmoved.

Having described the illustrative method.

embodying my invention, what I'claim as new and desire to secure 'by Letters Patout is:

Claims.

facturing artificial monoliths characterized by placing a sheet-like layer of fluxive concrete mixture of solid and liquid, constituents including cement on a surface; and vi- 'brating the same a suflicient length'of time to bring a layer of practically pure cement to said surface.

2. An. improvement in the art of manufacturing artificial monoliths characterized by placing on a mold a fluxive concrete mixture of liquid and solid constituents including cement, the-latter having a fineness greater than that ofany of the other solid constituents; and vibrating the mixture to settle cement to the face of the mold to provide a face closely simulating the character of the face of the mold.

the art of manue '3. An improvement in the art of manu-' faoturing artificial monoliths characterized placing a 'sheet-likelayer of fluxive concrete mixture of solid and liquid ingredients including cement on a surface; agitating the same a sufficient length of time to bring a layer of practically pure cement to said surface; and then uniting the latterto a back- 4. An improvement in the art of manufacturing artificial monoliths characterized by placing a sheet-like layer of flux'ive concrete mixture of solid and liquid ingredients, including cement, on a surface; agitating the same a suflicient length of time to bring a layer of (practically pure cement to said surface; an uniting" the latter to a backing of concrete mixture while both are adhesive. i

5. An improvement in the art of manufacturing artificial monoliths characterized by placing a sheet-like layer of fluxive concretermixture of solid and liquid ingredients, including cement, on a surface; agitating the same a suficient length of time to bring a layer of practically pure cementto "said surface; and then uniting the latter to a backing of concrete mixture of a different character while both are adhesive.

6. An improvement in the art of manufacturing artificial monoliths characterized by placing a sheet-like layer of fluxive concrete mixture of solid and liquid ingredients, including cement, on a surface, agitating the same a sufficient length of time to.

bring a layer of ractically pure cement to said surface; an uniting said layer while on said surface to a backing of concrete mixture while said layer and backing are adhesive.

facturing artificial monoliths which is char acterized by placing a thin la .er of wet. con crete mixture on a surface, vi rating the latter to drive air and water from said mixture, leaving the latter to stiffen somewhat, placing the plate with its layer in a mold, fillin a concrete mixture thereon, vibrating e plate and mold and leaving the molded form to harden.

9. A method of making forms of concrete characterized by placing a thin layer of wet concrete mixture on the surface of a plate, vibrating the latter to drive air and water from said mixture, leaving the latter to stiffen somewhat, placing and vibrating another layer on another plate, placing one of said plates on a side of a mold and the other on the bottom of said mold. filling the mold with a concretemixture, vibrating the whole and then .removing the mold and permitting the molded form to harden.

10. A method of making forms of concrete characterized by placing a layer of wet concrete mixture on a surface,

vibrating the latter to drive air and water from said mixture. leaving .the latter to stiffen somewhat. placing the surface with its layer in a mold, filling the latter with a concrete mixture, vibrating the whole and then removing the vmold and leaving the molded form to harden.

11. A methodof making forms of concrete characterized by placing on a plate a layer of wet concrete mixture comprising one partcement and two parts of gravel or crushed stone, vibrating said plate to drive air and water from said layer then leaving the latter to stifi'en somewhat. placing the plate withits layer in a mold; filling the I latter with a moist concrete mixture comprising one part cement, two parts sand and three parts crushed stone or gravel; vibrating the whole and removing the mold and leaving the molded form to harden.

12. A- methOd of making forms of concrete characterized by--placing on a pattern what. 5

a layer of wet concrete mixture comprising two parts of stony ingredients to one part of binding substance, vibrating the layer to drive air and some of the water from said mixture. leaving the latter to st-iifen someplacing the pattern with its layer in a mold; filling the latter with a moist mixture comprising two (parts sand, three parts ston ingredients an one part cement; vibratlng the pattern and mold and leaving the molded form to harden.

13. A method of. making forms of concrete characterized by placing a layer of wet concrete mixture on a plate, vibrating the latter to drive air and water from said mixture, permitting the latter to stifien somewhat; lacing the plate into a mold, filling the latter with a body of concrete mixture drier than said layer mixture; vibrating the mold and then leaving the molded form to harden;

14. An improvement inthe-artof manufeaturing artificial monoliths characterized by placing a coating of suet of beef on a pattern, placing a layer of wet concrete mixture on said pattern, vibrating the layer to set- 2 tle the mixture. on said pattern and drive air.

and water from said mixture; after an'iin% terval of a few minutes placing the layer and pattern in a mold, filling the latter'with and.mold and then permitting the form thus made to harden.

15. An improvement in the art of manufacturing artificial monoliths characterized by arranging a color orv colors on a pattern; placing a layer of wet concrete mixture on the latter; vibrating said pattern to settle the layer intimately in contact with said pat tern and spread said color or colors, and then permitting the mixture to harden.

16. An improvement in the art of manua concrete mixture, vibrating said pattern facturing artificial monoliths characterized by arranging a color or colors on a pattern or plate to simulate graining or marble, placing a layer of wet concrete mixture on said pattern or plate, vibrating the latter to drive air and some of the water from said mixture to settle the particles of the latter into intimate engagement with said pattern or plate and then permitting the mixture to harden.

17. A method of making forms of concrete characterized by covering a pattern with an insulation coating,-arranging colors thereon, placing a layer of Wet concrete mixture on said attermvibrating the latter to drive out air and some of the water from said mixture and settle the particles of the latter into intimate engagement with said pattern, permitting the mixture to stiffen somewhat: then introducing said pattern and layer into a mold, filling the latter with a moist concrete mixture, vibrating the mold and pattern and then removing the mold and permitting the form thus made to harden.

18. A method of making forms of concrete characterized by placing a wet layer of concrete mixture on a pattern or plate, vibrating the latter for about thirty seconds, then after a few minutes have elapsed placing the pattern or plate in a mold, filling a concrete mixture in the latter, vibrating the mold and pattern or plate for about sixty Seconds and then" removing the mold and permitting the form thus molded to harden.

19. A method of casting concrete walls characterized by placing a layer of wet concrete mixture on a plate, vibrating the latter to drive air and some of the water therefrom, placing the plate with its layer in a mold after said layer has stifl'ened somewhat; filling the mold with a concrete mixture, tamping down the latter and then removing said plate and mold after said mixture has set. a

20. An im rovement in the art of manufacturing artificial monoliths which is characterized by agitating a thin layer of fluxive material comprising liquid and solid conand backing are adhesive and then steaming the monolith thus formed.

21. An improvement in the art of manu-' facturing artificial monoliths characterized by placing on a lubricated surface a body of fluxive concrete mixture of solid and liquid constituents including cement; and vibrat-- ing the same to bring a layer of the cement to said surface.

In testimony whereof, I have signed my name to this specification, in the presence of two subscribing witnesses.

ANDREW JENSENJ;

Witnesses:

HENRY T. WILLIAMS, ROBERT H. KAMMLER. 

